Gate or door frame assembly and method of making a gate or door

ABSTRACT

A frame assembly for making a gate or door comprising an upper horizontal member, a lower horizontal member, a first vertical member and a second vertical member, one or more cylindrical members provided along the length of each of the upper and lower horizontal members, first connection means to connect an upper end of the first vertical to one end of cylindrical member provided along the length of the upper horizontal member, second connection means to connect lower end of the first vertical to one end of cylindrical member provided along the length of the lower horizontal member, third connection means to connect an upper end of the second vertical to a second end of cylindrical member provided along the length of the upper horizontal member and fourth connection means to connect a lower end of the second vertical to a second end of cylindrical member provided along the length of the lower horizontal member.

FIELD OF THE INVENTION

The present invention relates to a frame assembly for use in theconstruction of gates or doors and, more specifically, to a frameassembly adapted to provide the vertical and horizontal support membersof a gate or door and rotatably connect these members to a fixedstructural member.

BACKGROUND OF THE INVENTION

Gates are used to allow selective access through a wall or fence.Conventionally, gates are constructed as follows. Two vertical supportmembers and two horizontal support members are fastened together in arectangular shape to form what will be referred to herein as a gateframe. Fence boards or the like are fastened to the support members, andone of the vertical support members is typically attached by tow or morehinge assemblies to a structural member such as a wall or post. Doorsare similarly constructed with vertical and horizontal support membersfastened together to form what will be referred to herein as a doorframe. A sheet of plywood or the like covers one or both sides of thedoor frame.

Using conventional gate/door building techniques, fasteners such asnails or screws are driven through one support member into anothersupport member to form the corners of the gate box. Over time, the forceof gravity and wood shrinkage will cause these fasteners to loosen,allowing the gate/door frame to sag out of its desired rectangularshape.

Accordingly, metal L-brackets, wooden brace members, triangular piecesof plywood, and the like are often fastened to the adjacent ends of thesupport members to strengthen the inside corners of the gate/door frame.In other situations, a wire is placed in tension between the upperproximal and lower distal corners of the gate/door frame to support thelower distal corner of the gate frame and thereby reduce sagging of thegate or door. Such bracing techniques are somewhat effective but thewire is aesthetically unappealing and can produce frayed ends which arepotentially dangerous. In addition the bracing commonly employsfasteners that are susceptible to failure and it can be relatively timeconsuming to implement.

Another problem with conventional gate/door building techniques is thatfasteners such as nails or screws are similarly used to attach the hingeassemblies to the vertical support member adjacent to the structuralmember. The loads are transferred to the gate/door through the screwsplaced in tension. As the wood shrinks and the gate/door is opened andclosed, the fasteners under tension tend to loosen and may eventuallyfail.

As the hinge fasteners loosen, the entire gate/door assembly may sagrelative to the hinge assemblies and the structural members, even if thegate/door frame maintains its rectangular shape. The use of braces atthe corners of the gate/door frame will worsen sagging at the hingesbecause the materials and hardware used for bracing increase the weightof the gate/door; this increased weight increases the forces of gravityon the fasteners used to attach the hinge assemblies to the proximalvertical support member.

Various solutions have been proposed. One attempt was a steel gate frameproduct comprising distal and proximal brace members, with hinges beingattached to the proximal brace member. A gate assembly constructed usingthis product would use upper and lower horizontal wooden supportmembers, but would not use vertical support members. Instead, the distaland proximal brace members would form the structure of the verticalsides, with each size corresponding to a given distance between theupper and lower horizontal support members. The finished gate hasexcessive flex along the vertical plane of the gate. This flexing cancause the gate to twist making installation difficult. Exposed metalbracing are subject to rust and are aesthetically unattractive.

Another proposed solution was a set of four metal brackets as shown inCanadian Industrial Design Registration No. 83049 and No. 83050. Theseregistrations describe a bracket system for forming gate assemblies.Four separate brace members are provided, and two of the brace membersare rigidly attached to hinge assemblies. The brace members are adaptedto be attached to support members to form the corners of a gate framefunctioning as the structural portion of the gate assembly. The hingeassemblies are adapted to be rigidly attached to a fence post to allowthe gate assembly to pivot relative to the fence post. Gate assembliesof arbitrary height and width can be formed using this bracket systemalthough wooden members must be trimmed to accommodate weld filets ofthe brackets. As there is no direct connection between the horizontaland vertical wooden support members that can over time twist and warpindependently of each other. While the finished gate is extremely rigid,light weight and flex resistant, exposed metal bracing and parts aresubject to rust and are unattractive. Costs of manufacture, qualitycontrol at welded connections and shipping costs are additional problemsassociated with this product.

From the foregoing, it should be clear that one object of the presentinvention is to develop a method and frame for making a gate or doorthat is easy and inexpensive to use, and which allow significantflexibility in the final design of the gate or door assembly.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a frame for making agate or door that is extremely rigid, light weight, flex resistant andwith a minimum of exposed metal bracing and parts.

A further object of the present invention is to provide a frame formaking a gate or door with improved method of securing the hinges to theframe.

Thus in accordance with the present invention there is provided a frameassembly for making a gate or door comprising an upper horizontalmember, a lower horizontal member, a first vertical member and a secondvertical member, one or more cylindrical members provided along thelength of each of the upper and lower horizontal members, firstconnection means to connect an upper end of the first vertical to oneend of cylindrical member, second connection means to connect lower endof the first vertical member to one end of cylindrical member, thirdconnection means to connect an upper end of the second vertical memberto a second end of cylindrical member and fourth connection means toconnect a lower end of the second vertical member to a second end ofcylindrical member.

There is also provided in accordance with the present invention a kitfor making a frame assembly for making a gate or door to fit a roughopening comprising upper and lower horizontal members sized to permitthem to be cut to fit rough opening width, two vertical members sized topermit them to be cut to fit rough opening height, one or morecylindrical members provided along the length of each of the upper andlower horizontal members, connection means to connect the ends of thevertical members to the ends of the cylindrical members provided alongthe length of the upper and lower horizontal members and two or morehinges. Further features of the invention will be described or willbecome apparent in the course of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are shown in the drawings,wherein:

FIG. 1 is a perspective view of an assembly drawing for a frame assemblyfor making a gate or door in accordance with the present invention.

FIG. 2 is a front plan view of the horizontal and vertical members ofthe frame assembly of FIG. 1.

FIG. 3 is an enlarged view of a hinge attachment detail of the frameassembly of FIG. 1.

FIG. 4 is an enlarged perspective view of a portion of a horizontalmember of FIG. 3 with a channel to accept a cylindrical member.

FIG. 5 is an end plan view of the horizontal member of FIG. 4 with thecylindrical member in place ready to receive the support rod.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIGS. 1 to 5, generally one embodiment of a frameassembly for making a gate or door in accordance with the presentinvention is generally indicated at 1. The frame assembly comprises anupper horizontal member 2, a lower horizontal member 3, a first verticalmember 4 and a second vertical member 5. In the preferred embodimentillustrated when assembled, the horizontal 2, 3 and vertical 4, 5members form a rectangular frame. In the embodiment shown support rods6, 7 are provided for connecting the upper horizontal member 2 withfirst and second vertical members 4, 5. The support rods preferably aresteel rods with a cross section of at least ¼ inch. In order to connectthe support rods 6, 7 to the upper horizontal member 2 so that it isstrengthened against sagging, a longitudinal hole or channel 8 isprovided along the length of the upper horizontal member 2 for receivinga cylindrical member 10. The hole or channel 8 can be drilled, groovedor provided in some other manner. In the embodiment shown, channel 8 isformed by making a groove a third of the thickness of the upperhorizontal member 2 in the lower section 9 of said horizontal member 2along its length. In the embodiment shown the upper and lower horizontalmembers 2, 3 have nominal dimensions of 1.5×3.5×24 inches. In the casewhere a channel 8 is provided, and not a hole, means for securelypositioning the cylindrical member 10 within said channel 8 areprovided. Hole or channel 8 is sized and shaped to permit cylindricalmember 10 to pass through it. The combination support rod andcylindrical member are defined herein as the support member.

Other materials and dimensions for the support member are possible solong as it provides the necessary support to the frame assembly.Alternatively, one or more support members can be provided along thelength of each of the upper and lower horizontal members 2, 3 to furtherstrengthen the resulting frame and prevent sagging.

The lower horizontal member 3 is similarly provided with a channel 8 andsupport rods 6, 7.

Connection means i.e. the support rods which serve a double purpose areprovided to connect the upper and lower ends of the first and secondvertical members 4, 5 to opposite ends of the cylindrical membersprovided along the length of the upper and lower horizontal members 2,3. The upper end of vertical member 4 is provided with at least onehorizontal hole 14 sized and located to permit support rod 6 to passthrough. If a second support rod is provided in upper horizontal member2, a second horizontal hole can be located in the upper end of verticalmember 4 to permit the second rod to pass through. The upper end ofvertical member 5 is similarly provided with at least one horizontalhole sized and located to permit support rod 7 to pass through. If asecond support rod is provided in upper horizontal member 2, a secondhorizontal hole can be located in the upper end of vertical member 5 topermit the second rod to pass through.

Similarly, the lower ends of vertical members 4, 5 are provided with atleast one horizontal hole sized and located to permit support rods topass through. In the preferred embodiment a plurality of horizontalholes can be provided in the lower ends at six inch intervals to permitthe length of vertical members 4, 5 to be adjusted to accommodatedifferent sizes of frame assembly.

The present invention also provides for easy adjusting of the width ofthe frame assembly. By providing a cylindrical member 10 to a standardlength of 24 inches, for instance, considering that a narrower frame isquite rare and not that useful, it can be seen that the horizontalmembers 2, 3 can be longer and yet cut to length without having to dothe same with the cylindrical member 10. Once the horizontal member iscut to one's desired length, the cylindrical member 10 can easily bereinserted in said horizontal member for secured positioning thereinbefore accepting the support rods.

In order to assemble the frame assembly 1 for making a gate or door inaccordance with the present invention, the upper and lower horizontalmembers 2, 3 are cut to the desired length based on the width of thedesired gate or door. Usually the width of the opening is measured(“rough opening”) and the width of the finished frame assembly iscalculated at one inch narrower than the rough opening. The length ofthe horizontal members 2, 3 and the width of the two vertical supportmembers 4, 5 should equal one inch narrower than the rough opening. Forexample, where the vertical support members are made from 2×4 lumberhaving nominal dimensions of 1.5×3.5 inches, the horizontal members 2, 3are cut eight inches narrower than the rough opening. Similarly, thefirst and second vertical members 4, 5 are cut to the desired lengthbased on the height of the desired gate or door. Typically, this desiredheight is height of the fence or door opening less clearance required atthe bottom to permit the gate or door to open and close. The verticalmembers 4, 5, as noted, are preferably predrilled with horizontal holesat six inch intervals to accommodate various sizes of gates. In thepreferred embodiment the frame assembly is designed to build gates ordoors from three feet to six-feet high, the normal maximum required.Anything shorter than three feet typically does not require the addedstrength provide by the present invention. If a gate of a height thatdoes not meet the predrilled holes, for example a gate fifty two incheshigh, the verticals can be cut using the holes drilled at forty eightinches and the fence boards can hang down below the lower horizontalsupport member.

Discussing the upper section of frame 1, cylindrical member 10 issecurely positioned either in the channel or hole 8 of the horizontalmember 2 and is at least partially threaded for reciprocally receiving athreaded support rod 6.

On the hinged side of the frame 1, support rod 6 is inserted firstthrough hole 11 of hinge 12 then in hole 13 of upper end of verticalmember 4. Support rod 6 is now abutting cylindrical member 10 which ispositioned into the horizontal member 2 and ready to be screwed intocylindrical member 10. End of support rod 6 is tapered and thereforewill not affect the performance of the hinged frame when in use as itforms a snug fit.

At the other end of horizontal member 2, support rod 7 is first insertedthrough hole 14 of upper end of vertical member 5 then screwed intocylindrical member 10 thereby forming the upper section of the frame 1.It will be obvious to someone skilled in the art that the bottom sectionof frame 1 can now be constructed as discussed above.

It will be understood that by having the support rods 6, 7 of equallength that once screwed into the cylindrical member 10 said member 10will be centered relative to horizontal member 2 therefore providingequal support throughout for optimum performance. As well, thecombination of support rods and cylindrical member provides forflexibility and ease of use when it comes to adjusting the size of theframe.

The hinges can then be attached to a fixed structural member such as afence post or door jamb. The hinges can be located to have the gateswing in or out and a left or right opening gate or door.

Once the frame assembly is complete fence boards or facing material canbe fastened to one or both sides of the frame assembly to complete thegate or door. Braces can optionally be provided, if desired, in theinside corners of the assembled frame assembly 1 to provide additionalrigidity.

The frame assembly is preferably provided as a complete kit to build agate frame or door frame including all hardware and structural members.One kit can build any normal sized gate or door. The present inventiondoes not depend on steel brackets to provide strength but rather thesupport rods and cylindrical member combinations that run through thestructural members and used to tie the whole frame assembly together.The present invention provides an extremely strong gate or door with noexposed steel parts to rust or corrode other than the hinges. The designof the present invention is easier to use than the prior art bracketsystems and builds a superior gate that will not twist or warp as iscommon due to the use of fencing lumber which is green (not kiln dried).The present invention can be used with horizontal and vertical membersof different sizes and materials (including composite materials) withoutdeparting from the scope of the present invention.

In addition to garden or fence gates the present invention can be usedto build odd sized doors for garden and storage sheds, cold cellars,basements, storage lockers or other applications that require a customsize of door.

Although various preferred embodiments of the present invention havebeen described herein in detail, it will be appreciated by those skilledin the art, that variations may be made thereto without departing fromthe spirit of the invention or the scope of the appended claims.

1. A frame assembly for making a gate or door comprising an upperhorizontal member, a lower horizontal member, a first vertical memberand a second vertical member, one or more cylindrical members providedalong the length of each of the upper and lower horizontal members,first connection means to connect an upper end of the first verticalmember to one end of cylindrical member, second connection means toconnect lower end of the first vertical member to one end of cylindricalmember, third connection means to connect an upper end of the secondvertical member to a second end of cylindrical member and fourthconnection means to connect a lower end of the second vertical member toa second end of cylindrical member.
 2. A frame assembly according toclaim 1 wherein cylindrical members provided along the length of each ofthe upper and lower horizontal members are at least partially threadedand inserted through a longitudinal hole or channel provided along thelength of said upper and lower horizontal members.
 3. A frame assemblyaccording to claim 1 wherein said connection means are threaded rods. 4.A frame assembly according to claim 1, having two or more hinges securedto either the first vertical member or the second vertical member.
 5. Aframe assembly according to claim 4 having two or more hinges secured toeither the first vertical member or the second vertical member, whereinone end of a support member provided along the length of the upper andlower horizontal members secures a pair of hinges to the first or secondvertical member.
 6. A frame assembly according to claim 1 wherein thelower end of the first and second vertical members are provided with aplurality of horizontal holes at designated intervals.
 7. A kit formaking a frame assembly for making a gate or door to fit a rough openingcomprising upper and lower horizontal members sized to permit them to becut to fit rough opening width, two vertical members sized to permitthem to be cut to fit rough opening height, one or more cylindricalmembers provided along the length of each of the upper and lowerhorizontal members, connection means to connect the ends of the verticalmembers to the ends of the cylindrical members provided along the lengthof the upper and lower horizontal members and two or more hinges.